Pile fabric



May 17, 1955 R. c. GEBERT 2,708,458

PILE FABRIC v Filed March 14. 1952 3 Sheets-.Sheet l May 17, 1955 R. c. GEBERT 2,708,458

PILE FABRIC Filed March 14. 1952 3 Sheets-Sheet 2 lIIIHIlI IL R. C. GEBERT PILE FABRIC May 17, 1955 3 Sheets-Shea?. 3

Filed March 14. 1952 ...Hlm

mgm-@f PRE FABRIC Russell C. Geber-t, Elkins Park, Pa., assigner to James Lees and Sons Company, Bridgeport, Pa., a corporation of Pennsylvania Application March 14, 1952, Serial No. 276,541 7 Claims. (Ci. 139-405) This invention relates to an improved floor covering and more particularly to a carpet of the Wilton type that is characterized by exceptionally dense face pile and excellent binding for the tufts or loops.

ln the conventional Wilton fabric, it is customary to permit the pile yarns not brought up by the jacquard mechanism to remain dead or inactive in the ground or base fabric. This dead or buried yarn in the back of the carpet was useful only to give a more solid base fabric, but it did not materially improve the quality of the face ile.

p lt has been the practice to weave Wilton carpet with two or more ends of pile yarn per reed dent but to bring to the surface and over the pile forming wire only one end of pile yarn per dent for each pile forming wire inserted into the shed, the remaining ends of pile yarn being woven into the base fabric until called for because of a color change. in the above manner of weaving an appreciable percentage of the pile yarn was not effective over any one wire. in accordance with the present invention, l propose to bring multiple ends of pile yarn over the pile forming wires, in selected reed dents, and in a predetermined pattern to produce increased tuft density and improved wear characteristics, thus effectively using a greater percentage of the pile yarn both for cut or uncut pile. production.

In loop or uncut pile carpet where the pile yarn is not carried down to and around the bottom weft shot it has been found possible to pull down a number of pile loops because of insufficient loop bind. In weaving loop pile carpet by the new method, a minimum number of loops are formed from any one pile end before it is allowed to run dead in the back, for one or more pile wires, to provide a more positive bind. The preferred practice is to form not more than three pile loops or tufts before allowing the end to run dead for one or more pile wires, so that if a pile loop is pulled, not more than two other loops will be pulled down. in other words, I have found that if the warp yarns are brought up to form face loops or tufts at least once between every four upper weft shots, a much denser and longer wearing carpet is obtained. This improvement can be applied to either a two, three, four, or even tive frame carpet, and there are a wide range of variations that can be achieved for pattern effect within the scope of the present invention.

In the present embodiment of the invention, l have preferred to illustrate my improved fabric as applied to a Brussels type carpet having uncut pile loops; however, it will be understood that the invention may be applied equally well to other fabrics and particularly a cut pile fabric having tufts.

A primary object of the invention therefore is to provide an improved pile fabric of the Wilton or Brussels type characterized by excellent bind for the face pile warp ends and greatly improved wearing qualities.

A further object of the invention is to provide in a multi-frame pile fabric a plurality of warp pile ends in This fact is true in both cut and uncut pile each dent of 4the fabric, each of said pile ends being brought up to form face pile at least once every four double weft shots.

A further object of the invention is to provide an improved method for weaving a pile fabric characterized by excellent pile warp bind and wearing qualities.

A further object of the invention is to provide in a four frame pile fabric a repeat pattern in which the ratio of live yarn to inactive yarn is 11/2 to 21/2.

A further object of the invention is to provide in a four frame pile fabric a repeat pattern in which the ratio of live yarn lto inactive yarn is 2 to 2.

A further object of the invention is to provide in a three frame pile fabric a repeat pattern in which the ratio of live yarn to inactive yarn is 11/2 to 1%.

A further obiect of the invention is to provide in a three frame pile fabric a repeat pattern in which the ratio of live yarn to inactive yarn is 2 to 1.

A further object of the invention is to provide in a two frame pile fabric a repeat pattern in which the ratio of live yarn to inactive yarn is l/z to 1X2.

A further object of the invention is to provide in a two frame pile fabric a repeat pattern in which the ratio of live yarn to inactive yarn is 11/3 to Further objects will be apparent from the specification and drawings in which:

Fig. 1 is a schematic face view of a four frame fabric constructed in accordance with the present invention;

Fig. 2 is a warpwise section as seen at 2 2 of Fig. l;

Fig. 3 is a schematic face View of another four frame fabric constructed in accordance with the present invention;

Fig. 4 is a warpwise section as seen at l-4 of Fig. 3;

Fig. 5 is a schematic face View of a three frame fabric constructed in accordance with the present invention;

Fig. 6 is a warpwise section as seen at 6 6 of Fig. 5;

Fig. 7 is a schematic face view of a varied three frame fabric constructed in accordance with the present invention;

Fig. 8 is a warpwise section as seen at 8-8 of Fig. 7;

Figs. 9, 1l, and 13 are schematic face views showing different two frame fabrics woven in accordance with the present invention; and

Figs. l0, 12, and 14 are warpwise sections as seen respectively at iii-10 of Fig. 9, L12-12 of Fig. 11, and 14-14 of Fig. 13.

The invention comprises essentially the provision of a fabric that is characterized by a plurality of pile warp yarns in each reed dent. However, in contrast to the conventional manner of weaving Wilton or Brussels fabrics, each face pile end is brought up over the pile wire not less than once every four double weft shots. ln this manner a more dense and much more tightly bound carpet is provided.

It will be understood that a wide variety of fabric designs is possible in practicing my present invention. This applies not only to a two frame fabric but also to other fabrics using more than two colors. The attached drawings are intended to be illustrative only of some of the many variations in pattern that can thereby be achieved.

Referring now more particularly to the drawings, Fig. 1 shows a preferred embodiment of the invention using a four frame uncut Wilton weave. The Stoffers have been omitted from the showing of the drawings, but it will i be understood that such stutfer warps will ordinarily be included in accordance with conventional practice. Each dent designated, for example A, has four different pile warp yarn ends 15, 16, 17, and 1b. In the arrangement shown in Figs. l and 2 warp yarns 15 and 18 are brought up together between alternate weft shots W, W. The

differently colored pile yarns or frames 1S, 16, 17, and 18 have the following sequence per repeat in each dent:

15 16 and 18 17 three down one up two down one up two down one up one down one up two down one up two down one up one down one up one down one up one down one up Thus it will be seen that there are in this pattern 1%. active yarns, and 21/2 inactive yarns. This ratio is calculated by comparing the total number of raised loops with the number of empty spaces in the entire repeat pattern as shown in Fig. 1 or in a repeat for each dent. In the cross-sectional views, the upper weft shots are designated W, W and the lower weft shots W1, W1. These are bound by the double chain warps C and C1 in accordance with conventional practice. For each weave, l have illustrated a complete warpwise and weftwise repeat, but it is not believed necessary to renumber the same frame yarns in different dents.

Figs. 3 and 4 illustrate a variation in a four frame fabric in which all four ends in each reed dent repeat are raised twice and are down twice, which gives two active yarn ends and two inactive yarn ends. In this case, the separate warp yarns in a reed dent repeat are designated 19, 20, 21, and 22..

Figs. 5 and 6 illustrate my invention as applied to a three frame fabric having warp yarns 23, 24, and 25. In l this case, each warp yarn is up twice and down twice per reed bent repeat, but the ratio between active and inactive yarn ends is 11/z:11/2.

Figs. 7 and 8 illustrate a variation in a three frame fabric having pile yarns 26, Z7, and 28. n this case all ends are up twice and down once per reed dent repeat. This gives a completely solid face such as that of the fabric of Fig. 3 with a ratio of two active and one inactive yarn ends.

Figs. 9-14 all show variations of the invention in a two a frame fabric. The arrangement of Figs. 9 and 1() has warp pile yarns 29 and 3i). In this case each pile yarn is up three times and down once per reed dent repeat giving a ratio of 11/2:1/2 between the active and inactive ends.

Fig. 11 has warp yarns 31 and 32 also arranged with three up and one down in each reed dent repeat, but in this case the overlapped loops occur between consecutive weft shots whereas in Fig. 9 they occur between alternate weft shots. Fig. 13 has warp yarns 33 and 34 that are up twice and down once per reed dent repeat. In this case the ratio between active and inactive yarn is 11/312/3.

lt will be understood that additional variations may be achieved by twisting differently colored yarns to form a single warp pile end or each pile end may be of a distinct homogeneous color and the novel arrangement of the fabrics described above can be woven with the pile loops over non-cutting or cutting pile forming wires or any combination thereof.

The fabric of the present invention has the advantage of increased pile density without increasing the number of pile yarn ends. This in turn provides more effective use of the pile yarn in the face of the fabric and a much superior bind for the pile loops or tufts.

Having thus described my invention, I claim:

1. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and at least two pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, one of the pile warps projecting upwardly between a rst pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots, the other of the pile warps projecting upwardly between said first pair of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots whereby it does not project upwardly between said second pair of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper weft shots being identical in form and height.

2. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and at least two pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, one of the pile warps projecting upwardly between a first pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots and being contained within the backing fabric between a third pair of adjacent upper weft shots whereby it does not project upwardly between said third pair of adjacent upper weft shots, the other of the pile warps projecting upwardly between said irst and third pairs of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots whereby it does not project upwardly between said second pair of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper wefts being identical in form and height.

3. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and a plurality of pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, said fabric comprising at least three upper wefts in each repeat, one of the pile warps projecting upwardly between a first pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots in said repeat, a second of the pile warps projecting upwardly between said first pair of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots whereby it does not project upwardly between said second pair of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper wefts being identical in form and height.

4. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and a plurality of pile warps disposed between two adjacent ninder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, one of the pile warps projecting upwardly between a rst pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots, a second of the pile warps projecting upwardly between said first pair of adjacent upper weft shots and between a third pair of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots whereby it does not project upwardly between said second pair of adjacent upper weft shots, and a third of the pile warps being contained in the backing fabric between said first pair of pile warps whereby it does not project upwardly between said first pair of pile warps and projecting upwardly between both said second and third pairs of adjacent upper weft shots, the pile warps which project upwardly between each pair of adjacent upper wefts being identical in forrn and height.

5. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and at least four pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, said fabric comprising at least eight upper wefts in each repeat, one of the pile warps projecting upwardly between a rst pair of adjacent upper weft shots and between two additional pairs of adjacent upper weft shots in each repeat, a second of the pile warps projecting upwardly between said first pair of adjacent upper weft shots and being contained in the backing fabric between said additional pairs of adjacent upper weft shots, whereby it does not project upwardly between said additional pairs of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper wefts being identical in form and height.

6. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and a plurality of pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, said fabric cornprising at least four upper wefts in each repeat, one of the pile warps projecting upwardly between a first pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots in said repeat, a second of the pile warps projecting upwardly between said first pair of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots whereby it does not project upwardly between said second pair of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper wefts being identical in form and height.

7. A pile fabric comprising a plurality of upper and lower weft shots, a plurality of binder warps interwoven with the weft shots to form a backing fabric structure, and at least three pile warps disposed between two adjacent binder warps in the backing fabric and projecting upwardly between selected pairs of adjacent upper weft shots to constitute the pile surface, one of the pile warps projecting upwardly between a first pair of adjacent upper weft shots and between a second pair of adjacent upper weft shots, a second of the pile warps projecting upwardly between-said first pair of adjacent upper weft shots and being contained in the backing fabric between said second pair of adjacent upper weft shots, the pile warps which project upwardly between said first pair of adjacent upper wefts being identical in form and height.

References Cited in the file of this patent UNITED STATES PATENTS 467,633 Bollentin Jan. 26, 1892 1,139,495 Crossland May 18, 1915 1,688,341 Mason Oct. 23, 1928 1,714,104 Pearsall May 2l, 1929 2,120,895 Harvey June 14, 1938 2,477,248 Harding July 26, 1949 2,573,841 lGroat Nov. 6, 1951 2,599,293 Symonds June 3, 1952 FOREIGN PATENTS 273,409 Great Britain July 6, 1927 500,301 Great Britain Feb. 7, 1939 

1. A PILE FABRIC COMPRISING A PLURALITY OF UPPER AND LOWER WEFT SHORTS, A PLURALITY OF BINDER WARPS INTERWOVEN WITH THE WAFT SHOTS TO FORM A BACKING FABRIC STRUCTURE, AND AT LEAST TWO PILE WARPS DISPOSED BETWEEN TWO ADJACENT BINDER WARPS IN THE BACKING FABRIC AND PROJECTING UPWARDLY BETWEEN SELECTED PAIRS OF ADJACENT UPPER WEFT SHOTS TO CONSTITUTE THE PILE SURFACE, ONE OF THE PILE WARPS PROJECTING UPWARDLY BETWEEN A SECOND PAIR OF ADJACENT UPPER WEFT SHOTS AND BETWEEN A SECOND PAIR OF ADJACENT UPPER WEFT SHOTS, THE OTHER OF THE PILE WARPS PROJECTING UPWARDLY BETWEEN SAID FIRST PAIR OF ADJACENT UPPER WEFT SHOTS AND BEING CONTAINED IN THE BACKING FABRIC BETWEEN SAID SECOND PAIR OF ADJACENT UPPER WEFT SHOTS WHEREBY IT DOES NOT PROJECT UPWARDLY BETWEEN SAID SECOND PAIR OF ADJACENT UPPER WEFT SHOTS, THE PILE WARPS WHICH PROJECT UPWARDLY BETWEEN SAID FIRST PAIR OF ADJACENT UPPER WEFT SHOTS BEING IDENTICAL IN FORM AND HEIGHT. 